Closed-loop control and data acquisition system for comprehensive bridge assembly impact test bench

Abstract

The invention discloses a closed-loop control and data acquisition system for an impact test bench of a comprehensive bridge assembly, which belongs to an impact test device of an axle assembly and comprises a real-time feedback closed-loop control system and an intelligent data acquisition and self-adaptive multi-dimensional data analysis system. The real-time feedback closed-loop control system is in communication connection with the intelligent data acquisition and self-adaptive multi-dimensional data analysis system through the communication module; the intelligent data acquisition and self-adaptive multi-dimensional data analysis system comprises an input module, an output module and a remote monitoring interface module; the real-time feedback closed-loop control system comprises a control module and a driving module. According to the invention, the data accuracy and the test reliability are improved, and the loading force can be accurately monitored and adjusted, so that the data of the axle impact test are more accurate and the process is stable; the test precision, the adaptability and the data analysis depth of the test equipment are improved, and the problems that test data of existing equipment are prone to deviation, the loading mode is single, and data analysis is insufficient are solved.

Description

Technical Field

[0001] The invention relates to an impact test device for a vehicle axle assembly, in particular to a closed-loop control and data acquisition system for an integrated axle assembly impact test bench. Background Art

[0002] With the advancement of vehicle technology, the durability and safety requirements of axles are constantly increasing. Vehicle R&D and production departments usually need to conduct a large number of impact tests during the axle design process to detect its durability and deformation. Axle components are subject to various impacts and vibrations during vehicle driving. Impact tests can simulate these extreme conditions to ensure that axle components will not be damaged, cracked or deformed when impacted, thereby ensuring their structural integrity and safety. Impact tests can detect the fatigue resistance of axle components in long-term use and evaluate their durability and reliability under various harsh conditions. Through testing, potential problems can be discovered and solved in a timely manner, extending the service life of axle components and reducing maintenance costs. By simulating different impact environments and intensities and evaluating the performance differences of different materials and design schemes, it can provide important references for the design and material selection of axle components, optimize the design, select appropriate materials and structures, and improve their impact resistance.

[0003] However, most of the existing axle impact test equipment lacks real-time feedback closed-loop control and data adaptive analysis functions, making it difficult to meet the needs of high-precision and high-frequency testing under complex working conditions. This makes the existing equipment insufficient in test data accuracy, adaptability and automation, so it is necessary to develop a new test equipment that can provide higher accuracy and more comprehensive data support. Summary of the invention

[0004] With regard to the above-mentioned problems existing in the prior art, the purpose of the present invention is to provide a closed-loop control and data acquisition system for an integrated bridge assembly impact test bench to solve the problems raised in the above-mentioned background technology.

[0005] To achieve the above object, the present invention provides the following technical solutions:

[0006] The closed-loop control and data acquisition system of the integrated bridge assembly impact test bench includes a real-time feedback closed-loop control system and an intelligent data acquisition and adaptive multi-dimensional data analysis system, wherein the real-time feedback closed-loop control system is connected to the intelligent data acquisition and adaptive multi-dimensional data analysis system through a communication module; the communication module is used for real-time exchange of data between the real-time feedback closed-loop control system and the intelligent data acquisition and adaptive multi-dimensional data analysis system;

[0007] The intelligent data acquisition and adaptive multi-dimensional data analysis system includes an input module, an output module and a remote monitoring interface module;

[0008] The input module includes a user input unit, a force sensor unit, a displacement sensor unit and an analog signal conversion unit; the user input unit is used to input a force setting value and a displacement setting value; the displacement sensor unit is used to collect displacement data during the impact test of the integrated bridge assembly; the analog signal conversion unit is used to convert the collected impact force data and displacement data into an analog signal; the force sensor unit is used to collect impact force data during the impact test of the integrated bridge assembly;

[0009] The output module includes HIM display unit, data recording unit and alarm system;

[0010] The intelligent data acquisition and adaptive multi-dimensional data analysis system is connected to the remote monitoring device through the remote monitoring interface module;

[0011] The real-time feedback closed-loop control system includes a control module and a drive module;

[0012] The control module includes a data processing unit, an algorithm control unit and an output instruction unit; the data processing unit is used to process the force signal data and displacement signal data after analog conversion and compare them with the set value; the optimization algorithm unit is used to perform fuzzy control and adaptive control;

[0013] The driving module includes a force control driving unit and a displacement control driving unit; the driving module is used to control the driving of force and displacement.

[0014] As a further solution of the present invention: the user input unit includes a force setting value input unit and a displacement setting value input unit.

[0015] As a further solution of the present invention: the user input unit is communicatively connected with an external HIM input door and a host computer interface module; the HIM input door or the host computer interface module is used to input force data setting values ​​and displacement data setting values.

[0016] As a further solution of the present invention: the HIM display unit includes a real-time force value display unit, a real-time displacement display unit and an error display unit between a set value and a current value; the HIM display unit is used to display real-time force value data, real-time displacement data and the error between real-time data and set value data.

[0017] As a further solution of the present invention: the data recording unit includes a force-displacement curve storage unit and a historical data export unit; the force-displacement curve storage unit is used to store a curve made of real-time force and displacement data; the historical data export unit is used to export historical data.

[0018] As a further solution of the present invention: the alarm system includes an over-limit force alarm unit and an over-limit displacement alarm unit; the alarm system is used to alarm for over-limit force or over-limit displacement.

[0019] As a further solution of the present invention: the data processing unit includes a force signal processing unit, a displacement signal processing unit and a set value comparison unit;

[0020] The force signal processing unit includes a force signal filtering and denoising unit and a force value conversion and calibration unit; the force signal filtering and denoising unit is used to filter and denoise the force signal data after analog conversion; the force value conversion and calibration unit is used to convert the denoised force signal data into a standard form and calibrate;

[0021] The displacement signal processing unit includes a displacement signal filtering and denoising unit and a displacement value conversion and calibration unit; the displacement signal filtering and denoising unit is used to filter and denoise the displacement signal data after analog conversion; the displacement value conversion and calibration unit is used to convert the denoised displacement signal data into a standard form and calibrate it;

[0022] The set value comparison unit includes a current force value and a set force value comparison unit, and a current displacement value and a set displacement value comparison unit; the set value comparison unit is used to compare the current force value and displacement value with the set force value and displacement value.

[0023] As a further solution of the present invention: the algorithm control unit includes a PID control unit, a dynamic response adjustment unit and an optimization algorithm unit;

[0024] The PID control unit includes a force closed-loop control unit and a displacement closed-loop control unit; the PID control unit is used to realize force and displacement closed-loop control.

[0025] As a further solution of the present invention: the output instruction unit includes a force drive adjustment unit and a displacement drive adjustment unit; the output instruction unit is used to adjust the force drive and the displacement drive.

[0026] As a further solution of the present invention: the force control drive unit includes a hydraulic servo valve and a hydraulic cylinder actuator; the force control drive unit is used to control the hydraulic servo valve and the hydraulic cylinder actuator

[0027] The displacement control drive unit includes a motor driver and a motor screw system; the displacement control drive unit is used to control the motor driver and the motor screw system.

[0028] Compared with the prior art, the present invention has the following beneficial effects:

[0029] The present invention improves the accuracy of data and the reliability of testing, can accurately monitor and adjust the loading force, so that the data of the vehicle bridge impact test is more accurate and the process is stable; it provides a scientific basis for the optimization of vehicle bridge design; the present invention significantly improves the test accuracy, adaptability and data analysis depth of the test equipment, and solves the problems of the existing equipment test data prone to deviation, single loading method and insufficient data analysis. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] Figure 1 The system framework diagram of the closed-loop control and data acquisition system of the integrated bridge assembly impact test bench disclosed in the embodiment.

[0031] Figure 2 The present invention is a structural schematic diagram of a closed-loop control and data acquisition system of a comprehensive bridge assembly impact test bench disclosed in an embodiment.

[0032] Figure 3 The present invention is a structural schematic diagram of a closed-loop control and data acquisition system of a comprehensive bridge assembly impact test bench disclosed in an embodiment.

[0033] Figure 4 The present invention is a structural schematic diagram of a closed-loop control and data acquisition system of a comprehensive bridge assembly impact test bench disclosed in an embodiment. DETAILED DESCRIPTION

[0034] The following will clearly and completely describe the technical solutions in the embodiments of the present invention in conjunction with the drawings in the embodiments of the present invention; it is obvious that the described embodiments are only part of the embodiments of the present invention, not all of the embodiments. Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without creative work are within the scope of protection of the present invention.

[0035] In the description of the present invention, it should be noted that, unless otherwise clearly specified and limited, the terms "installed", "provided with", "connected", and "connected" should be understood in a broad sense; for example, it can be a fixed connection, a detachable connection, or an integral connection, a mechanical connection, or an electrical connection, a direct connection, or an indirect connection through an intermediate medium, or the internal communication of two components. For ordinary technicians in this field, the specific meanings of the above terms in the present invention can be understood according to specific circumstances.

[0036] See also Figure 1-4, the closed-loop control and data acquisition system of the integrated bridge assembly impact test bench includes a real-time feedback closed-loop control system and an intelligent data acquisition and adaptive multi-dimensional data analysis system. The real-time feedback closed-loop control system is connected to the intelligent data acquisition and adaptive multi-dimensional data analysis system through a communication module; the communication module is used to exchange data between the real-time feedback closed-loop control system and the intelligent data acquisition and adaptive multi-dimensional data analysis system in real time; the real-time feedback closed-loop control system monitors the stress and deformation of the axle during the impact loading process through high-precision pressure sensors and displacement sensors. The monitoring data is fed back to the control system in real time, and the control system dynamically adjusts the action unit of the hydraulic system according to the deviation between the actual data and the set value. Through this closed-loop control mechanism, the parameters in the test loading process can be adaptively adjusted to keep the loading force and displacement within the preset range, ensuring that the stress and deformation during the impact test meet the test requirements, and improving the accuracy and stability of the test data.

[0037] The intelligent data acquisition and adaptive multi-dimensional data analysis system collects multiple variable information such as pressure and displacement in real time through sensors, and processes the data of each variable synchronously. The control system automatically adjusts the loading unit according to the real-time stress of the workpiece under test at different impact stages, so that its stress state fits the test set value to ensure the accuracy of the test process. The system uses a multi-dimensional data analysis algorithm to generate two-dimensional and three-dimensional data curves such as stress distribution diagrams and fatigue life prediction models of the axle assembly under different working conditions. All test data can be exported to the database to facilitate subsequent test result comparison and working condition simulation analysis.

[0038] The intelligent data acquisition and adaptive multi-dimensional data analysis system includes an input module, an output module and a remote monitoring interface module;

[0039] The input module includes a user input unit, a force sensor unit, a displacement sensor unit and an analog signal conversion unit;

[0040] The user input unit includes a force setting value input unit and a displacement setting value input unit; the user input unit is connected to the external HIM input door and the host computer interface module for communication; the HIM input door or the host computer interface module is used to input the force data setting value and the displacement data setting value; it is convenient for subsequent work;

[0041] The force sensor unit is used to collect impact force data during the impact test of the integrated bridge assembly;

[0042] The displacement sensor unit is used to collect displacement data during the impact test of the integrated bridge assembly;

[0043] The analog signal conversion unit is used to convert the collected impact force data and displacement data into analog signals;

[0044] The output module includes HIM display unit, data recording unit and alarm system;

[0045] The HIM display unit includes a real-time force value display unit, a real-time displacement display unit, and a set value and current value error display unit; the HIM display unit is used to display real-time force value data, real-time displacement data, and the error between real-time data and set value data;

[0046] The data recording unit includes a force-displacement curve storage unit and a historical data export unit; the force-displacement curve storage unit is used to store a curve made of real-time force and displacement data; the historical data export unit is used to export historical data;

[0047] The alarm system includes a force over-limit alarm unit and a displacement over-limit alarm unit; the alarm system is used to alarm for force over-limit or displacement over-limit;

[0048] The intelligent data acquisition and adaptive multi-dimensional data analysis system is connected to the remote monitoring device through the remote monitoring interface module; when working, the overall experimental situation is monitored through the remote monitoring device, and the information is transmitted to the intelligent data acquisition and adaptive multi-dimensional data analysis system to facilitate the use of subsequent work and ensure safety.

[0049] The real-time feedback closed-loop control system includes a control module and a drive module;

[0050] The control module includes a data processing unit, an algorithm control unit and an output instruction unit;

[0051] The data processing unit includes a force signal processing unit, a displacement signal processing unit and a set value comparison unit; the data processing unit is used to process the force signal data and displacement signal data after analog conversion, and compare them with the set value;

[0052] The force signal processing unit includes a force signal filtering and denoising unit and a force value conversion and calibration unit; the force signal filtering and denoising unit is used to filter and denoise the force signal data after analog conversion; the force value conversion and calibration unit is used to convert the denoised force signal data into a standard form and calibrate;

[0053] The displacement signal processing unit includes a displacement signal filtering and denoising unit and a displacement value conversion and calibration unit; the displacement signal filtering and denoising unit is used to filter and denoise the displacement signal data after analog conversion; the displacement value conversion and calibration unit is used to convert the denoised displacement signal data into a standard form and calibrate it;

[0054] The set value comparison unit includes a current force value and a set force value comparison unit, and a current displacement value and a set displacement value comparison unit; the set value comparison unit is used to compare the current force value and displacement value with the set force value and displacement value;

[0055] The algorithm control unit includes a PID control unit, a dynamic response adjustment unit and an optimization algorithm unit;

[0056] The PID control unit includes a force closed-loop control unit and a displacement closed-loop control unit; the PID control unit is used to realize force and displacement closed-loop control;

[0057] The optimization algorithm unit is used for fuzzy control and adaptive control;

[0058] The output command unit includes a force drive adjustment unit and a displacement drive adjustment unit; the output command unit is used to adjust the force drive and the displacement drive;

[0059] The driving module includes a force control driving unit and a displacement control driving unit; the driving module is used to control the driving of force and displacement;

[0060] The force control drive unit includes a hydraulic servo valve and a hydraulic cylinder actuator; the force control drive unit is used to control the hydraulic servo valve and the hydraulic cylinder actuator;

[0061] The displacement control drive unit includes a motor driver and a motor screw system; the displacement control drive unit is used to control the motor driver and the motor screw system;

[0062] The test bench control system of the present invention is divided into two operating modes: manual control and automatic control, and can be switched freely. The program writing interface is simple, visual, and highly operable; the present invention can adapt to the axle assembly test of different models and specifications by replacing or adjusting the axle installation tooling; the test bench of the present invention can manually add monitoring limits for custom variables; by monitoring whether the value of the custom variable exceeds the limit, an alarm, shutdown, etc. are made; the present invention has the function of indicating the operating status and real-time display of measurement data;

[0063] The present invention diagnoses equipment faults, issues alarms or automatically shuts down, and collects and saves data before shutting down. For fault alarms, it is required that the diagnosis results can be displayed on the control cabinet or computer, and the troubleshooting methods for common faults are introduced in the manual;

[0064] The function of collecting, recording and saving the operation measurement data of the present invention;

[0065] The present invention has the functions of compiling, editing and modifying the test conditions and the operation program or the operation mode on the computer.

[0066] The parameter test range and accuracy of the comprehensive bridge assembly impact test bench of the present invention are as follows: displacement measurement range 0-50mm; pressure measurement range 0-1MN; pressure sensor accuracy level 0.05; the display accuracy of the accumulated bench hours and running bench hours of the test bench is 0.1 hour.

[0067] The present invention provides a comprehensive impact test bench for axle assemblies. Through real-time feedback closed-loop control and intelligent data acquisition and analysis systems, the equipment can dynamically monitor and adaptively adjust the loading state of the axle during the test, thereby improving the accuracy of the data and the reliability of the test. The equipment can meet the impact test requirements of various axle assemblies, output multi-dimensional data analysis results, and provide more scientific data support for axle structure optimization.

[0068] The present invention can accurately monitor and adjust the loading force through the real-time feedback closed-loop control system of the present invention, so that the data of the vehicle bridge impact test is more accurate and the process is stable; and the intelligent data acquisition and multi-dimensional analysis system generates a complete stress distribution and life prediction model through adaptive adjustment and multi-dimensional analysis algorithm, providing a scientific basis for the optimization of vehicle bridge design. In general, the present invention significantly improves the test accuracy, adaptability and data analysis depth of the test equipment, and solves the problems of the existing equipment test data prone to deviation, single loading method and insufficient data analysis.

[0069] It will be apparent to those skilled in the art that the present invention is not limited to the details of the exemplary embodiments described above, and that the present invention can be implemented in other specific forms without departing from the spirit or essential features of the present invention. Therefore, the embodiments should be considered exemplary and non-restrictive from any point of view. The scope of the present invention is defined by the appended claims rather than the above description, and it is intended that all changes falling within the meaning and scope of the equivalent elements of the claims be included in the present invention, and any reference numerals in the claims should not be considered as limiting the claims involved.

[0070] In addition, it should be understood that although the present specification is described according to implementation modes, not every implementation mode contains only one independent technical solution. This description of the specification is only for the sake of clarity. Those skilled in the art should regard the specification as a whole. The technical solutions in each embodiment may also be appropriately combined to form other implementation modes that can be understood by those skilled in the art.

Claims

1. Comprehensive bridge assembly impact test bench closed-loop control and data acquisition system, characterized by: It includes a real-time feedback closed-loop control system and an intelligent data acquisition and adaptive multi-dimensional data analysis system, wherein the real-time feedback closed-loop control system is connected to the intelligent data acquisition and adaptive multi-dimensional data analysis system through a communication module; the communication module is used for real-time exchange of data between the real-time feedback closed-loop control system and the intelligent data acquisition and adaptive multi-dimensional data analysis system; The intelligent data acquisition and adaptive multi-dimensional data analysis system includes an input module, an output module and a remote monitoring interface module; The input module includes a user input unit, a force sensor unit, a displacement sensor unit and an analog signal conversion unit; the user input unit is used to input a force setting value and a displacement setting value; the displacement sensor unit is used to collect displacement data during the impact test of the integrated bridge assembly; the analog signal conversion unit is used to convert the collected impact force data and displacement data into an analog signal; the force sensor unit is used to collect impact force data during the impact test of the integrated bridge assembly; The output module includes HIM display unit, data recording unit and alarm system; The intelligent data acquisition and adaptive multi-dimensional data analysis system is connected to the remote monitoring device through the remote monitoring interface module; The real-time feedback closed-loop control system includes a control module and a drive module; The control module includes a data processing unit, an algorithm control unit and an output instruction unit; the data processing unit is used to process the force signal data and displacement signal data after analog conversion and compare them with the set value; the optimization algorithm unit is used to perform fuzzy control and adaptive control; The driving module includes a force control driving unit and a displacement control driving unit; the driving module is used to control the driving of force and displacement.

2. The closed-loop control and data acquisition system for the integrated bridge assembly impact test bench according to claim 1 is characterized in that: The user input unit includes a force setting value input unit and a displacement setting value input unit.

3. The closed-loop control and data acquisition system for the integrated bridge assembly impact test bench according to claim 2 is characterized in that: The user input unit is connected to the external HIM input door and the host computer interface module for communication; the HIM input door or the host computer interface module is used to input the force data setting value and the displacement data setting value.

4. The closed-loop control and data acquisition system for the integrated bridge assembly impact test bench according to claim 1 is characterized in that: The HIM display unit includes a real-time force value display unit, a real-time displacement display unit and a set value and current value error display unit; the HIM display unit is used to display real-time force value data, real-time displacement data and the error between real-time data and set value data.

5. The closed-loop control and data acquisition system for the integrated bridge assembly impact test bench according to claim 4 is characterized in that: The data recording unit comprises a force-displacement curve storage unit and a historical data export unit; the force-displacement curve storage unit is used to store a curve made of real-time force and displacement data; the historical data export unit is used to export historical data.

6. The closed-loop control and data acquisition system for the integrated bridge assembly impact test bench according to claim 5 is characterized in that: The alarm system comprises an over-limit force alarm unit and an over-limit displacement alarm unit; the alarm system is used to give an alarm for over-limit force or over-limit displacement.

7. The closed-loop control and data acquisition system for the integrated bridge assembly impact test bench according to claim 6 is characterized in that: The data processing unit includes a force signal processing unit, a displacement signal processing unit and a set value comparison unit; The force signal processing unit includes a force signal filtering and denoising unit and a force value conversion and calibration unit; the force signal filtering and denoising unit is used to filter and denoise the force signal data after analog conversion; The force value conversion and calibration unit is used to convert the denoised force signal data into a standard form and calibrate it; The displacement signal processing unit includes a displacement signal filtering and denoising unit and a displacement value conversion and calibration unit; the displacement signal filtering and denoising unit is used to filter and denoise the displacement signal data after analog conversion; the displacement value conversion and calibration unit is used to convert the denoised displacement signal data into a standard form and calibrate it; The set value comparison unit includes a current force value and a set force value comparison unit, and a current displacement value and a set displacement value comparison unit; the set value comparison unit is used to compare the current force value and displacement value with the set force value and displacement value.

8. The closed-loop control and data acquisition system for the integrated bridge assembly impact test bench according to claim 7 is characterized in that: The algorithm control unit includes a PID control unit, a dynamic response adjustment unit and an optimization algorithm unit; The PID control unit includes a force closed-loop control unit and a displacement closed-loop control unit; the PID control unit is used to realize force and displacement closed-loop control.

9. The closed-loop control and data acquisition system for the integrated bridge assembly impact test bench according to claim 8 is characterized in that: The output instruction unit comprises a force drive adjustment unit and a displacement drive adjustment unit; the output instruction unit is used to adjust the force drive and the displacement drive.

10. The closed-loop control and data acquisition system for the integrated bridge assembly impact test bench according to claim 9 is characterized in that: The force control drive unit includes a hydraulic servo valve and a hydraulic cylinder actuator; the force control drive unit is used to control the hydraulic servo valve and the hydraulic cylinder actuator The displacement control drive unit includes a motor driver and a motor screw system; the displacement control drive unit is used to control the motor driver and the motor screw system.

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